Manufacturing Process Laboratory 0

MODULE 5
BENCH WORK

OBJECTIVES

1. Students are able to understand about bench work process.

2. Students are able to understand bench work tools.

OUTLINES

5.1 Introduction of Bench Work Process

5.2 Classification of Some Bench Work Operation
5.3 Tool Used
5.4 Measuring Instruments
5.5 Safety Equipment

BASIC THEORY

Introduction of Bench Work

Bench work is any activity that the production process is done manually, without using
the engine, worked on the desk. The activities included in the bench work are chipping, filling,
scrapping, grinding, marking, drilling, reaming, tapping, dying, sawing. the process of bench
work practice required skill and precision in the execution of the workpiece, so students can
make the bench work practice as a measure to prepare for potential labor as industry
professionals.

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 Classification of Some Bench Work
Operation
The Bench Work Operations are classified into several process below.
1. Chipping
Chipping is working on materials by a wedge-shaped tool (the chisel) in order to
separate or chip material. The cutting effect of the chisel is achieved by hammering on
the head end of the chisel, which is an energy and time consuming operation.

Figure 5.1 Chipping

(Source: http://static.republika.co.id)

2. Hand Scraping
Hand Scraping is the process of using a scraper held in the hands to remove
small amounts of metal from a precision surface so as to provide an accurate bearing
surface to within some tolerance. The hand scraping tools usually used are made from:
a. High Speed Steel (HSS)
b. Tool Steel
c. Carbide Steel

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 The tools can be use to scraping a brass, casted steel, bronze, etc. The tools can’t be
used to scrap the steel, for steel we can use tools that are made from hard metal. Every
tools has a different shape on the point it depends on what it used for, example: the
tools to scrap casted steel is different with the tools to scrap brass, the tools to scrap
casted steel and to scrap brass has a different angle. So we can conclude that the shape
of the tools is depend on the material.

Figure 5.2 Hand Scraping

(Source: http://www.practicalmachinist.com)

3. Reaming
Reaming is a process of enlarging the hole with a very high accuracy dimension.
Reaming process use reaming machine. Before the reaming process, the material
should have been drilled.

Figure 5.3 Manual Reaming

(Source : www. Magneticdrillingmachines.com)
Reaming process have a few type, there are hand reamer, machine reamer,
chucking reamer, fluting reamer, expanding reamer and adjustable reamer.

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 4. Sawing
Sawing is a basic machining process in which chips are produced by a
succession of small cutting edges, or teeth, arranged in a narrow line on a saw “blade”.
Here are some kind of sawing.
a. Crosscut Saw
Crosscut is used to cut across the grain of the wood. Crosscut saw has a teeth
with an angle back and beveled edge.

Figure 5.4 Crosscut Saw

(Source : www.hobby-market.eu)

b. Rip Saw
Rip saw is used to cut parallel to the direction of the wood. The Rip saw cut
teeth doesn’t have an angle beveled nor beveled. Instead, the teeth bend left
and right in the alternating pattern.

Figure 5.5 Rip Saw

(Source : www.toolinfoandreviews.com)

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 c. Keyhole Saw
Keyhole is used to cut hole for pipe, electrical outlets or fixtures in floors,
walls, and ceilings. Keyhole saw teeth can chew through tough material like
drywall.

Figure 5.6 Keyhole Saw

(Source : www.neteberg.eu)

d. Coping Saw
Coping saw is used to cut curves and other intricate shapes, don’t forget to
bust out the coping saw.

Figure 5.7 Coping Saw

(Source : www.static.axminster.co.uk)

e. Back Saw
Back saw have a stiffening metal rib on the edge opposite the cutting edge.
This allows for better control and more precise cutting than with other
types of saws.

Figure 5.8 Back Saw

(Source : www.s3.amazonaws.com)

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 f. Hack Saw
The hacksaw is used to cut steel and other metals. It can also be used to cut
plastics, although it is not normally used to cut woods. Blades are supplied
in two lengths, 250 mm and 300 tmm.

Figure 5.9 Hack Saw

(Source : www.stanleytools.com)

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 Tool Used

These are some kind of tools usually used in Bench Work Process:
Tabel 5.1 Bench Work Equipment
Tool Name Figure Description
This tool is used to cut a variety of
alloy (alloy) and steel with low
Hack Saw
carbon content.

This tool is used with a hammer to

make a point mark on a piece of steel
before using a drill. The signs point
Centre punch
to prevent the drill so as not to
deviate from the desired location of
the holes.
are names used for a type of coated
abrasive that consists of sheets of
Sandpaper paper or cloth with abrasive material
glued to one face.

Vice is a clamp tool to clamp the

workpiece to be filed, chiseled,
sawed, on tap, in sney, etc. By
Vice
rotating the shaft (handle) vice, then
vice mouth will open or removing
the workpiece that is being done.
Thread die used to make the screw
Thread die in a piece of circle iron or for fixing
screw that is damaged.

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 Tabel 5.2 Bench Work Equipment (cont.)
Tool Name Figure Description
Thread tap is a tool for cutting
threaded to fit the bolt or bolt
cropping partner. This tool can be
Thread tap
used to fix the nut or the same tool
that thread irregular (cross
threaded).
a tool with a characteristically
shaped cutting edge (such as wood
chisels have lent part of their name
to a particular grind) of blade on its
Chisel
end, for carving or cutting a hard
material such as wood, stone, or
metal by hand, struck with a mallet,
or mechanical power.

Policap was sandpaper shaped a cap

to ease sanding a workpiece which
Policap have the hole. Sandpaper stamp set
this used on a stamp holder and air
die grinder as backend .

Handheld power tools used for

grinding, sanding, honing,
Die Grinder polishing, or machining material
(typically metal, but also plastic or
wood).

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 Tabel 5. 1Bench Work Equipment (cont.)
Tool Name Figure Description

Hammer is
Ball Peen Hammer a tool or device
that delivers a
blow (a sudden
impact) to an
object. Hammers
Chisel Hammer are used to strike
Hammer a job or a tool.
They are made of
forged steel and
Straight Peen the handle is
Hammer made by wood of
various size and
shapes to suit
Soft Hammer various purposes.

Measuring Instrument

1. Steel Ruler
Steel Ruler is used for taking linear measurements of blanks and articles to an accuracy
of range from 1.0 to 0.5 mm. It consists of a strip of hardened steel having line graduations
etched or engraved at interval of fraction of a standard unit of length.

Figure 5. 10 Steel Ruler

(Source : www.hultrafos.com)

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 2. Divider
Divider is used to measuring, transferring, marking off the distance. These are the way
to use divider.
a. Loosen the nut.
b. Set the distance of the divider.
c. Tighten the nut.
d. Plug one of the sharp part to the surface.
e. Turn the handle until it marks.

Figure 5. 11 Divider
(Source : www.northentool.com)
3. Micrometer
Micrometer is one of the measure equipment that can be used to measure the length,
thickness, and the outer diameter of a part with the accuracy 0.001 mm.

Figure 5. 12 Micrometer
(Source : www.fowlerprecision.com)

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 4. Vernier Caliper
Vernier caliper is a measure equipment with the accuracy 0.01 mm. Vernier caliper
divided into 2 part : the constant part and the moving part.

Figure 5. 13 Vernier Caliper

(Source : www.chicagobrand.com)

Safety Equipment

These are some safety equipment usually used in manufacturing process laboratory.
Tabel 5. 3 Safety Equipment
Safety Equipment Figure Function

Protect eyes from dangerous

Goggles things like chips, chemical,
etc.

Safety Mask Filter the bad air quality.

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 Tabel 5. 2 Safety Equipment (cont.)
Safety Equipment Figure Function

Protect body from chemical,

Wearpack
cuts, or burn.

Protect foot from danger

like chemical, heavy things
Safety Shoes
sharp things, burn, etc.

Protect hands from whether

Hand gloves from chemicals, cuts or
burns.

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 REFERENCES

Black, J. (2008). DeGarmo's Material and Process in Manufacturing. United State of America:
Jhon Wiley and sons,inc.
Kapakjian, S. (2009). Manufacturing Engineering and Technology 6th edition. united state of
america: pearson education.
Laboratory, A. M. (2016). Modul Praktikum Proses Manufaktur. Bandung: Manufacturing
Process Laboratory.
Wagiran. (2011). Modul Praktek Kerja Bangku. Yogyakarta: Universitas Negri Yogyakarta.

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